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Reinforcing factory tool compartment

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Reinforcing factory tool compartment

PostAuthor: Makeshift » Sat Sep 06, 2014 7:55 am

OK, so I typed up this long step by step of how I did this, but then my computer crashed, so here is a shorter version. The pictures make it all pretty self explanatory and it's a 20min job.

When i got my '98 XV750, the toolbox was missing it's lid. On getting another compartment, it looks like the hinges and latch were a weak spot, fatiguing with use and vibration. My goal was to reinforce the unit enough to not have it break again. One thing to note is that the lid has a lip around it's edge which mates to a groove in the base. Knowing this, all I needed was something to hold the lid against this groove, as long as there is that pressure, the lid will not slide around on the base.

To strenthen the hinges, I thought of using leather or nylong straps, but the simplest solution came in the form of crimp connectors and a length of wire, all pop-rivetted into the plastic. Make sure the wire is tight with the lid closed.

Image

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To reinforce the latch, I used the same elastic fittings as pickup trucks use to hold the tonneau covers onto the tray. I don't know the official term for them, but once you see them and describe their intended purpose almost anyone will know what I'm talking about. Again; rivetted though the plastic, using washers where required.

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The whole thing back on the bike.

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I just use it as somewhere to put the factory toolkit (perfect fit) and a few other bits (spare plugs, zipties, duct tape).

:;:
Jeff | '98 XV750

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Re: Reinforcing factory tool compartment

PostAuthor: Jake » Sat Sep 06, 2014 10:01 am

That's a nice idea. Does the cover fit over that shock cord button ?
_______________________________________________________________________
“It ain’t what you don’t know that gets you in trouble.
It’s what you know for sure that just ain’t so.”

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Re: Reinforcing factory tool compartment

PostAuthor: Makeshift » Sat Sep 06, 2014 10:26 am

Jake wrote:That's a nice idea. Does the cover fit over that shock cord button ?


To be perfectly honest, that never even crossed my mind. :o: :ops:
Used left side covers are few and far between down under (guess they all fall off) and I can't justify the cost of a new one just for cosmetics. The shock cord buttons I got were about 12mm high, but there are smaller sizes available.
Jeff | '98 XV750

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Re: Reinforcing factory tool compartment

PostAuthor: Jake » Sat Sep 06, 2014 11:48 am

Makeshift wrote:
Used left side covers are few and far between down under (guess they all fall off)
They are getting harder to find. They only fall off if they are not attached properly.
_______________________________________________________________________
“It ain’t what you don’t know that gets you in trouble.
It’s what you know for sure that just ain’t so.”

~Mark Twain
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Jake
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Re: Reinforcing factory tool compartment

PostAuthor: gleam » Sat Sep 06, 2014 10:22 pm

Very nice idea. I was looking at mine too and thought it was quite flimsy. I've read on here that it's not a tool box, it's for paperwork. I didn't get the toolkit with my bike so I don't know how big that is. I was going to make an inner box out of some fabric lunchbox type material, and then figure out a way to reinforce the latch.

My left side cover is staying on my wall until I get some new grommets and decide if I want to use the wire method of securing it or not. For now I've taped up this plastic box to keep it from flopping open.
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